Face mask

ABSTRACT

A face mask has a mask main body, horizontal nose bridge material, vertical shapeable material and two loops. The mask body includes an outer layer formed by panels of breathable material such as fabric, a shapeable nose bridge material and an inner layer formed by panels of breathable material such as fabric, installed with a vertical shapeable material at the central portion. The mask structure has a three dimensional curving profile which creates a larger breathing chamber between the user&#39;s face and the mask. The mask&#39;s unique profile provides an improved wearing and breathing experience, making it more comfortable than the conventional face masks. Additional layers such as filters can be inserted optionally between the outer layer and inner layer to increase the protection and serve different purposes of use required by the user. The vertical shapeable material can also help secure the position of the inserted layers.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not Applicable

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates to a face mask with a structure that creates a larger chamber between the inner surface of the mask and the face of the user.

Description of Related Art

There are a variety of face masks and protective devices known in the art whose design and performance characteristics vary in accordance with the field of application and approved standards. Generally known as face masks, facemasks, simple face masks, surgical masks or respirators, these protective masks and devices are produced in different sizes and shapes, made of different types of materials and fabrics provided with different types of wearing or attachments, and formed with one or several filtering layers in order to achieve different levels of protection and purposes of use.

The major functions of a face mask are to prevent harmful substances in the air inhaled by the user while breathing, prevent the user from exhaling harmful substances into the environment, and stop direct contact of harmful substances released through the nose or mouth with other people. In order to make the mask works effectively, fitting properly on the user's face is important, because leakage affects the protection level of the mask. On the other hand, the user usually wears a mask for a period of time, therefore wearing and breathing comfortably are both important.

A conventional face mask usually only has a single horizontal nose bridge wire to be deformed to suit part of the user's face and it stays very close to or comes in direct contact with the user's face, mouth and nose, during speaking and breathing. The water vapour in the breathed-out air and saliva tends to condense or accumulate on the mask's inner surface and moisturize the inner layer material, which easily makes it uncomfortable to wear and potentially reduces the filter layer performance, especially when the wet surface is in direct contact with the user's face, skin, mouth and nose. The narrow space between the face mask and user's face, mouth and nose also reduces the air-flow area especially during inhalation which makes the inner layer material of the mask might draw toward the user's face, mouth and nose, resulting in difficult breathing.

Some face masks allow users to insert additional filters to serve different purposes of use and level of protection. The inserted additional filter in such mask might move around, be folded or not stay stable inside the mask when wearing it for a period of time, which easily makes it uncomfortable to wear and potentially reduces the filtration performance.

The present invention overcomes the problems of conventional masks and provides a more comfortable wearing experience by making the mask stay secured for a period of time with the choice of increased level of protection and serve different purposes of use defined by users

BRIEF SUMMARY OF THE INVENTION

The present invention seeks to provide solutions to the above-mentioned problems by installing a vertical shapeable material at the central portion of the face mask, in addition to a shapeable nose bridge material. Users can gently bend and shape the vertical shapeable material outward to make a C shape configuration, which renders the mask in a more three-dimensional form in fitting different users' face and create a larger chamber between the face mask and the user's face, mouth and nose at user's control, furthermore, preventing the water vapour in the breathed-out air/saliva from condensing or accumulating easily on the mask's inner layer surface and moisturizing it, making breathing easier and more comfortable than using conventional face mask while properly covering the face to reduce leakage. The specially designed moldable C shape mask helps make the mask fits most face profiles by simple bending step(s). Since each user's face shape varies, different sizes are provided.

On the other hand, an additional layer such as a filter can be inserted between the outer layer and inner layer of the face mask, when the vertical shapeable material installed in the inner layer is bended outward in C shape away from the user's face, user can ensure the filter between the mask is secured in place and fixed in the position because of the added structure and the three dimensional formed generated.

For the purpose of versatility, there are two versions—a disposable version and a reusable version. The mask structure allows the vertical shapeable material and horizontal nose bridge material in the face mask to be either non-removable or removable. Users can take the shapeable material out such as wire or plastic thin plate when washing the mask or replacing it with a new one when it is damaged.

Due to different users' face shape and purposes of use in different environment may vary, the material(s), sizes, number of layers used, making method(s) might also vary. Therefore one or more vertical shapeable materials might need to be put in one of, or more or any layers of the mask, preferable in the inner layer of the mask, at the central portion of the mask to create and maintain the chamber structure. Loops are secured to the two shorter side edges of the mask, which could be strips of conformable material such as elastic straps, fabric, etc for engaging a user's ears, and thus serve as earloops or tie around the user's head.

The loops attached to the main body via the two loop hole spaces created at the two shorter edges are interchangeable, allowing for replacement by the user optionally. The loops, depending on the design, could be ear loops by running around the back of the user's ears, or head loops by running around the back of the user's head either by ties or loop over. The material of the loops is adjustable to elastic bands, straps, fabric etc.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

In the accompanying drawings, which show the best model currently contemplated for carrying out the invention:

FIG. 1 is a plan view showing the outer layer surface of the face mask.

FIG. 2 is a plan view showing the inner layer surface of the face mask.

FIG. 3 is an elevation view showing the left side of the outer layer surface of the folded face mask.

FIG. 4 is a perspective view showing the structure of the face mask.

FIG. 5 is an elevation view of a user wearing the mask with respect to FIG. 4.

FIG. 6 is a schematic cross-sectional view of the face mask.

FIG. 7 is an elevation view of a user wearing the mask with respect to FIG. 6 on how to secure the additional inserted layer.

FIG. 8 is a plan view of the mask showing alternative loops structures as head loops.

FIG. 9 is an elevation view of a user wearing the mask showing alternative loops structures as head loops with respect to FIG. 8.

FIG. 10 is a plan view of the mask showing alternative loops structures as tie straps.

FIG. 11 is an elevation view of a user wearing the mask showing alternative loops structures as tie straps with respect to FIG. 10.

DETAILED DESCRIPTION OF THE INVENTION

The face mask of the invention is described in detail and with particular reference to the drawings. The mask is intended to create and maintain a more three-dim ensional and larger chamber between the mask and user's face by using the vertical shapeable material such as wire or plastic thin plate 14 installed at the central portion inside the mask. The vertical shapeable material 14 optionally put in one of or more or any of the layer in the mask to create the chamber, preferably inside the inner layer 16, which the layer is closer to the user.

As the user's face shape and purposes of use in different environment vary, the material(s), sizes, number of material layers use, making method(s) might also vary, therefore one or more than one vertical shapeable material may need to be put in one of or more or any layers in the mask, preferably in the inner layer 16 of the mask at the central portion, which an area around or near the vertical central line of the mask, but not limited to the vertical central line of the mask, of the mask to create and maintain the chamber structure. Although only one vertical shapeable material 14 is shown in the drawing, two or more pieces can be provided optionally.

Referring to FIG. 1 which is a plan view showing the outer layer 15 surface of the face mask. It shows the outer layer is formed by one left and one right panel material such as paper, fabric and non-woven fabric etc. attached together by different methods such as stitching, welding, thermal bonding, adhesive bonding and laminating etc. with a nose bridge material such as wire or thin plate 11 on the top edge between the outer layer 15 and inner layer 16 of the mask and two loop hole spaces 12 and 13 created on two shorter edges of the mask which can be donned loop materials such as elastic straps, fabric, etc 20 and 21.

Referring to FIG. 2 which is a plan view showing the inner layer 16 surface of the face mask. It shows that the inner layer 16 is formed by one left and one right panel material such as paper, fabric and non-woven fabric etc. with a vertical shapeable material 14 installed at the central portion of the inner layer 16 of the mask and a loop hole spaces 12 and 13 created on two shorter end sides of the mask which can be donned loop materials such as elastic straps, fabric, etc. 20 and 21.

Referring to FIG. 3 which is an elevation view showing the left side of the outer layer surface of a folded face mask. The face mask can be folded along the central line of the mask. The face mask structure provided by this invention includes a mask main body comprising of two-layered material 15 and 16, a shapeable nose bridge material 11, a vertical shapeable material 14 and two loop hole spaces 20 and 21. The mask main body can be bent into a C-shape to cover the nose and mouth of the user. The vertical shapeable material 14 installed at the central portion of the mask main body is in a C-shape to create a larger chamber between the inner layer 16 surface of the mask and the face of the user.

Referring to FIG. 4 which is a perspective view showing the structure of the face mask showing the face mask has a total of four panels which each layer is formed by two panels. Flexible nose bridge adjustment material, such as wire or plastic thin plate 11, is installed near the top edge of the mask between the outer layer 15 and inner layer 16, while a vertical shapeable material such as wire or plastic thin plate 14 is installed in the inner layer 16, and is fixed at the central portion. When the face mask is worn, the vertical shapeable material 14 can be bent into a C-shape to create a larger chamber between the inner layer surface 16 of the mask and the face of the user, avoiding water vapour and saliva from condensing or accumulating easily on the inner layer surface.

There is a space between the outer layer 15 and inner layer 16, where filter can be inserted optionally to increase the mask protection and serve different purposes of use. A hole 18 in the inner layer 16 allows the user to remove the vertical shapeable material 14 any time, depending on the design of or the purpose of use of the mask such as disposable or reusable usage, the hole might be close so the vertical shapeable material 14 is not removable. A hole 19 between the outer layer 15 and inner layer 16 allows users to remove the horizontal shapeable nose bridge material 19 any time. Depending on the design of or the purpose of use of the mask, the hole might be close so the horizontal nose bridge material 19 is not removable.

FIG. 5 is an elevation view of a user wearing the mask with respect to FIG. 4, which depicts the large chamber created between the inner layer 16 surface of the mask and the face of the user, with the vertical shapeable material 14 being bent into a C-shape and the horizontal shapeable nose bridge material 11 is shaped to ensure that the upper edge of the mask main body nicely conforms to the contours of the user's face, such that no gap can form and the face mask remains airtight. Wherein when in worn state, the mask is expanded in a three dimensional form created and maintained by the C-shape profile, vertical shapeable material and horizontal shapeable nose bridge material provide a larger breathing chamber between the face mask and the user's face, mouth and nose.

Referring to FIG. 6, which is a schematic cross-sectional view of face mask and FIG. 7 is an elevation view of a user wearing the mask with respect to FIG. 6 on how to secure the additional inserted layer, which depicts a horizontal nose bridge material 11 fixated between the outer layer 15 and inner layer 16 near the upper edge of the mask main body and a vertical shapeable material 14 fixated in the inner layer and at the central portion of the mask main body. Space 17 between the outer layer 15 and inner layer 16 allows the optional insertion of additional layer 30 such as fabric, insulation or filter etc. which the additional insert layer 30 is not part of the mask structure.

Alternative Securement Features

FIG. 8 is a plan view of the mask showing alternative loop structures and FIG. 9 is an elevation view of a user wearing the mask showing alternative loop structures with respect to FIG. 8 which depicts the loop hole spaces of 12 and 13 created on two shorter edges of the mask which can be donned loop materials such as elastic straps, elastic bands, fabric, etc. This construction loops 31 is available for engaging a user's head and thus serve as head loops.

FIG. 10 is a plan view of the mask showing alternative loop structures as tie straps and FIG. 11 is an elevation view of a user wearing the mask showing alternative loop structures as tie straps with respect to FIG. 10 which depicts the loop hole spaces of 12 and 13 created on two shorter edges of the mask which can be donned a soft resilient material 32-35 such as straps, elastic bands, fabric, etc. This construction using the tie material 32-35 is available for securing the face mask to the user's head and wrapping the opposite sides of the user's head, and it is tied to one another. 

What is claimed is:
 1. A face mask comprising a mask main body of at least one outer layer, at least one inner layer, a partial opening between the outer and inner layer, one loop hole space at each shorter end of the main body with a total number of two loops going through the loop hole spaces, a vertical shapeable material along the central portion of the mask, a horizontal nose bridge shapeable material along the top edge of the mask.
 2. The face mask according to claim 1, wherein folded portions folded in a direction along the central portion.
 3. The face mask according to claim 1, wherein the main body is profiled into a C-shape at the central portion towards the shorter straight edges at both sides of the main body when folded flat.
 4. The face mask according to claim 1, wherein the main body is expanded into a three dimensional form created by the C-shape profile, vertical shapeable material and horizontal nose bridge material in worn state.
 5. The face mask according to claim 1, wherein the said vertical shapeable material is a structure, creates and maintains a larger breathing chamber between the user's face, mouth and nose.
 6. The face mask according to claim 1, wherein the said horizontal shapeable material is a nose bridge structure configured to provide a worn state in which is placed against the user's face and at least a portion of the nose.
 7. The face mask according to claim 1, wherein the loops connected to the right and left shorter edges of the mask main body.
 8. The face mask according to claim 4, wherein when in worn state, the three dimensional form created and maintained by the C-shape profile, vertical shapeable material and horizontal shapeable nose bridge material, provides a larger breathing chamber between the face mask and the user's face, mouth and nose.
 9. The face mask according to claim 8, wherein the larger breathing chamber and distance created reduce the condition that water vapour in the breathed-out air and saliva to condense or accumulate on the mask's inner surface and moisturize the inner layer of the face mask, which easily makes the face mask uncomfortable to wear and potentially reduces the filter layer performance, especially when the wet surface is in direct contact with the user's face, skin, mouth and nose.
 10. The face mask according to claim 8, wherein the larger breathing chamber created, provides an improved wearing experience, making it more comfortable and fit better on the user's face than the conventional face masks.
 11. The face mask according to claim 8, wherein the user can configure the shape of the face mask to his/her face profile that circumscribes the breathing chamber region via the vertical shapeable material and horizontal shapeable nose bridge material in worn state to prevent leakage that affects the protection level of the face mask.
 12. The face mask according to claim 1, wherein the partial opening is created for the insertion of additional layer by the user.
 13. The face mask according to claim 1, wherein one or more layer of fabric, insulation and filter can be inserted between the outer layer and the inner layer by the user to increase the protection and other purposes of use.
 14. The face mask according to claim 1, wherein the inserted layer is secured in place and fixed in the position by of the C-shape profile, the vertical shapeable material at the central portion and the horizontal nose bridge material because of the non-linear three dimensional form created. 